CONFORMS

WITH
EUROPEAN
REGULATIONS

OPERATOR’S
MANUAL
MANUAL

Wet Kit
2
 CONTENTS

• Correct use.............................................................. 1

• Identification.......................................................... 3,4

• Familiarisation.......................................................... 5

• Safety.................................................................... 6-8

• Operating pressure.................................................. 2

• Controls................................................................ 8, 9

• Operate the equipment.................................... 10, 11

• How to lower the body........................................... 11

• When driving.......................................................... 11

• Safety during maintenance.................................... 12

• Maintenance.................................................... 13 -15

• Oil (and filling the oil tank)...................................... 17

• Problem solving............................................... 19, 20

• Spare parts & service............................................. 20

33
 SPARE PARTS & SERVICE

Use only genuine Edbro parts from Edbro service dealers.

Refer to the online Dealer Location at www.edbro.com for a full
list of service dealers and distributors.

Always quote the component part number and serial number

when ordering parts or seeking advice.

4
 CORRECT USE

This hydraulic kit has been specified to be assembled to a

vehicle to carry out one or more specific tasks i.e. Tipper,
Walking floor or Ejector or a combination of these.

It is the operator’s responsibility to ensure that the equipment is

coupled to the appropriate equipment.

This manual is intended as a general guide for safe use but more
specific safety guidance should be provided by the bodybuilder
depending on the nature of the equipment to which it is
connected.

The bodybuilder can also advise on the pressure and flow

requirement of the connected equipment such as the hoist
capability and road traffic regulations.

55
 OPERATING PRESSURE

The equipment must only be operated up to a maximum rated

pressure shown on the equipment to which the hydraulic kit is
attached.

For dual pressure systems it is important to ensure that the

correct pressure is selected and connected appropriately.

NEVER TRY TO ALTER THE PRESSURE SETTING OF THE

RELIEF (OVERLOAD) VALVE. THIS IS AN ESSENTIAL SAFETY
DEVICE NORMALLY PRESET AT THE FACTORY.

• If in doubt contact the bodybuilder or EDBRO

6
 Tipper / Walking Floor Wet kit: Drawing and Bill of materials
Fittings Core Parts Kit
Item Part No. Description CKTWF Check pressure rating for tipper
1 Adapter HP 3/4” - 3/4” BSP(male) 3
2 Bounded Seal Washer 3/4” 5
3 NR611/27 Adapter HP 1” - 3/4” BSP(male) 2
4 NR611/43 Adapter HP 1” - 1” BSP(male) 7 Remote Mount Valve Kit
NR1637 Equal Tee 1”-1”-1” BSP (female) 2
20
5 21
6 DPP45H/SC Bonded Seal Washer 9
7 Relief Valve 250 bar 3/4” BSP (female) 1
VO11250H
22 13
8 NR1663 Bulkhead Adaptor HP 3/4” BSP(female) 1
9 NR1662 Bulkhead Adaptor HP 1” BSP(male) 2
4 25 24
10 NR611/41 Adaptor HP 1-1/2”- 1” BSP(male) 2 6
11 DPP45K/SC Bonded Seal Washer 1-1/2” 2
i. Tipper feed / Return 15
12 PM478 In-line Filter 30 bar 10 micron 1-1/2” BSP(female) 1
13 AF97 Filler / Breather Assembly 1
14 PM598 3-Way ii. Ejector
Diverter / Walking
Ball Valve floor
1” BSP (female) return
1 23
15 CT201M075P165 CT201 Tipper Valve with speed control, 165 bar 1
16 SA2905/V2 Mount for Cab
SeatEjector
Floor / iii. Control
/ Walking 1
floor feed 21
Remote Mount Valve Kit 16 20
Item Part No. Description RMV4 3
20 DPP45F/SC Bounded Seal Washer 3/4” 2
21 NR611/42 Adaptor HP 3/4” -3/4“ BSP (male) 2
22 NR627 Adaptor Elbow HP 3/4”male - 3/4“ BSP (Female) 1
23 OP87/8/84 HP Oil Hose, 2 Straight ends 215 bar 84” long 3/4“ 1 6
24 NR1687 Plug 3/4” BSP (male) 1 4
25 DPP45D/SC Bounded Seal Washer 1/2” 1 5

77
Hoses Kit
Item Part No.
A OP87/6/36/HP
B OP87/6/48/HP
C OP87/6/84/HP
D OP87/8/84
E OP87/8/60
F OP87/8/36
G OP87/6/60
4
Description HKTWF01
D 4
XHP Oil Hose, 2 Straight ends 350 bar 36” long 3/4“ 2 E
XHP Oil Hose, 2 Straight ends 350 bar 48” long 3/4“ 1 5 Oil Tank
E 10
XHP Oil Hose, 2 Straight ends 350 bar 84” long 3/4“ 1 Please refer to
HP Oil Hose, 2 Straight ends 210 bar 84” long 1“ 3
11
F Oil Tank specification sheet
HP Oil Hose, 2 Straight ends 210 bar 60” long 1“ 2
Return
HP Oil Hose, 2 Straight ends 210 bar 36” long 1“ 1
9 12 3
11 2
HP Oil Hose, 2 Straight ends 215 bar 60” long 1“ 1 10
IDENTIFICATION

Coupling Accessories B

1 Suction Line
D 2
3 Ensure Top
4 24 7
6 2 is open
6 1
2
A Pump
4 8
6

i C
G
ii 1 6 14
2
iii 3 Check pressure rating for the Ejector / Walking floor
QDC
Please refer to
Quick Disconnect couplings
Specifcation sheets
Ensure Divertor valve is in correct position
 IDENTIFICATION

Serial numbers for Edbro PTO, pumps and valve are stamped on
the casing or on a seperate plate.

The serial number should be quoted in all correspondence.

FAMILIARISATION

Before using this equipment, familiarise yourself with the

key features. The position of the hydraulic parts may vary
depeneding on specficiation.

Before putting into service, confirm that the equipment is in good

working order.

Check:

• Hoses and fittings for abrasion and leaks.

• check oil level

• check, where applicable, that quick detachable couplings are

tight

• check PTO warning light is working

• Diverter valve is switched to correct position for the

equipment to be operated.

8
 SAFETY

Tipping is always hazardous and sometimes dangerous.

Vehicles can be overturned by sticking loads, poor ground

conditions,high cross winds or bad practices such as tipping on a
side slope. So:
HOW TO LOWER THE BODY
• do not tip until you have read and understood this manual
Make sure that no-one is in the danger area (see page 7). Then:
• remember the hoist (tipping gear) is designed to lift; it is not a
• SLOWLY move the tipper lever out of 'hold' towards 'lower'; this
stabiliser will automatically disengage the PTO and the warning light will
go out. If automatic PTO disengagement isn't fitted, switch the
• if the vehicle
PTO tooverturns, any damage
'out' before driving off to the hoist is the RESULT
and not the CAUSE of the turnover
• regulate the speed the body comes down by moving the lever
towards 'hold' to slow it down or towards 'lower' to speed its
• avoid descent by following the safety code on pages
accidents 6 and 7
• when the body is down, move the lever back to 'hold'
• it is the responsibility
• lock the taildoor of the operator to ensure that drivers are
suitably trained in the use of this equipment.
• if fitted, raise the stabiliser legs.

Warning
DO NOT :DRIVE
Take care
OFFto guardTHE
UNTIL against
BODY the
ISescape of high
FULLY DOWN.
pressure oil
MAKE SURE THAT THE PTO IS DISENGAGED BEFORE
DRIVING OFF.

WHEN DRIVING

When UNLADEN leave the cab control in HOLD to minimise body

bounce.

99
 SAFETY CODE

ALWAYS NEVER

• Check the hoses are correctly • Overload or Shake the load free
connected.
• Alter the pressure setting of the relief
• Ensure the divertor valve is in the (overload) valve
correct postion.
• Put the tipper lever in ‘tip’ unless you are
actually tipping
• Keep the tyres at the correct
pressure
• Tip in high winds or on a side slope
• Spread the load evenly in the
• Operate the equipment with trailer
Body
connected.
• Before tipping make sure your
• Tip with the body within 5 metres of
truck is on firm, level ground
overhead power lines
• Make sure the danger area is clear
• Drive off with the body up or the PTO
of people and obstructions (refer
engaged. This could damage the
opposite)
equipment
• During tipping, stay in the cab
• Leave the vehicle with the ignition key in
at the controls; if danger signs
develop (for example, if the body starts
• Go under a raised loaded body or Leave
to lean to one side or the load sticks)
the body up overnight
immediately lower the body
• Go under a raised empty body
• Prevent the discharging load from
(Unless it is propped)
piling up and fouling on the taildoor
by driving forward very slowly by
• Steam clean the exposed cylinder tubes,
no more than a metre at a time
this will cause corrosion
• Just before loading, move the
• Climb on the equipment by any
control lever to lower to ensure
means other than that provided by the
that no oil is trapped in the cylinder
bodybuilder.
and the full load rests on the
chassis. • Never power wash near the breather

Extra caution • Operate the equipment without trailer

connected.
10
SAFETY CODE

Always ensure that no

person, animal or other
equipment is within this
area when operating

11
11
 CONTROLS

The hydraulic kit works best if the vehicle is fitted with matching
Edbro hydraulics (PTO, pump, valves, oil tank, pipes and controls).

The following options are available for PTO and tipper control.
• Factory fitted PTO
• Edbro/ JOST PTO
• Pneumatic Dual Hoist and PTO control
• Single Hoist control

The PTO control switch is fitted with a PTO engaged warning light.

The EDBRO Dual tipper control is a lever with four safety features:

• A spring-loaded device stops it from being accidentally

moved into ‘raise’ or ‘lower’
• A spring return to ‘hold’ from ‘raise’ position, known as a
deadman’s handle function, ensures the driver keeps his hand
on the tipper control all the time the body is being raised
• When the lever is moved from ‘hold’ towards ‘lower’, the
pto is *automatically disengaged; this internal mechanical
feature prevents pto, pump or gearbox damage if you forget to
disengage the pto before driving off
• Controlled lowering (feathering) regulates speed of descent for
loaded or part-loaded bodies.

This type of control is recommended for conformity with

European standards. Other controls are available but, if used,
the bodybuilder will need to ensure that all Essential Safety
Requirements are covered by other means. For example,
separate controls are available (fig. b).

*Alternative combined controls without automatic PTO disengagement feature

(for spreading or static discharge applications) are available.

12
 CONTROLS
CONTROLS

Tipper lever with

spring return
safety feature

PTO engaged
warning light

PTO switch

Fig. a. Combined PTO & tipper air controls

Fig. b. Separate tipper air control

139
13
 OPERATE THE EQUIPMENT

CHECK DIVERTER VALVE IS IN THE CORRECT POSTITION.

Make sure the handbrake is on, the gear lever is in neutral, the
tipper lever is in ‘hold’ and the PTO switch is ‘out’.

• Refer connected trailer to equipment operator manual. Then:

• If fitted, lower the rear stabiliser legs

• Unlock the taildoor or grain hatch (taking care to stand clear)
• Start the engine and make sure the air pressure
Is at the level recommended by the manufacturer
• Remain in the cab until the tipping operation is complete
• Depress the clutch* and wait 4 seconds
(8 seconds for a gear box with a rear mounted pto)
• Press the safety latch and switch the pto ‘in’
HOW TO
(the warning light LOWER
will come on)THE BODY
• Release the clutch
Make sure• that
Make sure
no-one no-one
is in the danger is within thepage
area (see danger area (see page 7)
7). Then:
• Move the tipper lever to ‘raise’ and hold in position.
• SLOWLY move the tipper lever out of 'hold' towards 'lower'; this
Releasing pressure
will automatically disengage the onPTO
the and
leverthe will stoplight
warning the willbody lifting
go•out.
Raise the body
If automatic PTOsmoothly by varying
disengagement the
isn't fitted, engine
switch the revs but
PTONEVER EXCEED
to 'out' before driving off1100RPM
• Prevent
• regulate the the
the speed discharging
body comesloaddownfrom
by movingpiling
theup and fouling the
lever
Taildoor by driving forward very slowly by no more than
towards 'hold' to slow it down or towards 'lower' to speed its
descent
A metre at a time
• when the body is down, move the lever back to 'hold'
• * Iftheyou
lock have
an automatic gearbox, the PTO operation will be
taildoor
different. Refer to the PTO installer for specific instructions.
• if fitted, raise the stabiliser legs.

Warning Maximum
DO NOT:DRIVE OFFengine
UNTIL revs
THE therfore
BODY ISpump
FULLY revs & flow should be
DOWN.
limited
MAKEby the
SUREapplication
THAT THE in the
PTOfirst
IS instance & thenBEFORE
DISENGAGED by the limit of the pump
DRIVING
& the suctionOFF.
line size used. Excess speed can cause damage to the pump &
gearbox. Refer to edbro for support & advice on maximum pump speeds.
WHEN DRIVING
14
 MAINTENANCE

WEEKLY
Make sure the body is down, the handbrake is on and the engine
is switched off. Then top up the oil in the tank to dipstick level
with clean hydraulic oil (refer page 17).

MONTHLY
Where appropriate, check that the quickly detachable couplings
seal when uncoupled.
Replace any worn or damaged flexible pipes.
Make sure all flexible pipes are secured to the chassis and are
not hanging loose.

Tighten any loose pipe connections.

Check and tell your Edbro service dealer if:
• Oil is leaking from the tipper valve, PTO, pump or flexible
HOW TO LOWER THE BODY
pipes
• Air is leaking from the air pipes
• Air is leaking continuously from the controls
Make sure that no-one is in the danger area (see page 7). Then:

• SLOWLY
THREE MONTHLYmove the tipper lever out of 'hold' towards 'lower'; this
will automatically disengage the PTO and the warning light will
Use go
spanners to check
out. If automatic PTOthe tightness of
disengagement isn'tthe fixing
fitted, bolts
switch the on the
tipper valve,
PTO to 'out'PTO and
before brackets.
driving off
• regulate the speed the body comes down by moving the lever
YEARLY 'hold'often
(more
towards in itdusty
to slow downorordirty conditions)
towards 'lower' to speed its
and refill the tank with clean hydraulic oil (refer page 17).
Draindescent
In• order
whento
theprotect the environment,
body is down, ensure
move the lever back that no oil is spilled
to 'hold'
when draining, and old oil is disposed of correctly. Replace filter
• lock the taildoor
element (if fitted).
• if fitted, raise the stabiliser legs.
Warning : Take care to guard against the escape
DO NOT DRIVE OFF UNTIL THE BODY IS FULLY DOWN.
of highSURE
MAKE pressure oil. Wear
THAT THE PTO ISprotective
DISENGAGED equipment
BEFORE to
prevent oil contacting the skin.
DRIVING OFF.

15
15
WHEN DRIVING
 MAINTENANCE

Check pipes for leakage or restriction Check Condition of Filter

Check oil level

Check
mountings
Replace Filter as recommendation
are secure

Ensure valve
is open

Check not restricted

Pump
Check for leaks & ensure
mounting screws are tight
QDC
Please refer to
Quick Disconnect couplings
Specifcation sheets

16
 MAINTENANCE

7 Maintenance Instructions
Category Instructions Weekly Monthly Quarterly Annually

Check and re-fill hydraulic oil


Replace tank filler breather filter  
Oil
Drain and refill oil tank with new hydraulic oil 

Replace oil filter if fitted  

Check hose pipe condition, and replace
when necessary 
Check pipes are secured and not hanging
Hydraulic loose 
Couplings /
Pipes
Check for oil leaks 
Re-Tighten pipe connections 
Connecting Tighten fixing bolts for tipper valve, PTO and
bolts tank mounting brackets 
Check condition and re-tighten tank straps 

Edbro MUB 020 006 EN- (REV--) 12-2017 41

7 Maintenance Instructions
Category Instructions Weekly Monthly Quarterly Annually
Pneumatic
Components
Check for leaks and correct operation 
Check for leaks, damage and correct
Pump
operation 
Check for noisy operation 
Check for oil leaks, damage and correct
PTO
operation 
Brackets Grease articulating joints 
 In very dusty environments replace the return line filter element and filler-breather elements monthly.

Dirty oil is the enemy of a hydraulic system. The cleaner the oil, the ADVICE!
more efficiently the equipment will operate and the longer the life It is recommended that the oil is replaced after the first
will be. Always use clean hydraulic oil for topping up or changing six months of operation, annually thereafter.
the oil in the tank.
Please dispose of oil according to local regulations and in an
environmentally friendly manner.
Check and tell your Edbro service provider if:

• Oil is leaking from the hydraulic equipment

• Air is leaking from the air pipes
• Air is leaking continuously from the controls

42
17
17
MUB 020 006 EN- (REV--) 12-2017 Edbro
 HOW TO LOWER THE BODY

HOWis in
Make sure that no-one TO theLOWER THE
danger area (seeBODY
page 7). Then:

• SLOWLY move the tipper lever out of 'hold' towards 'lower'; this
will automatically disengage the PTO and the warning light will
Make suregothat
out.no-one
If automatic PTO
is in thedisengagement
danger areaisn't page
fitted,
(see 7). Then:
switch the
PTO to 'out' before driving off

• SLOWLY• regulatemove the the

speedtipper lever
the body comesoutdown
of ‘hold’ towards
by moving ‘lower’;
the lever
towards 'hold' to slow it down or towards
this will automatically disengage the pto and the warning 'lower' to speed its light
descent
will go out. If automatic pto disengagement isn’t fitted, switch
the •ptowhen the body
to ‘out’ is down,
before move
driving offthe lever back to 'hold'
• Regulate
• lockthe speed the body comes down by moving the
the taildoor
lever • towards ‘hold’
if fitted, raise theto slow itlegs.
stabiliser down or towards ‘lower’ to
speed its descent
• When the body DO NOT is down,
DRIVE OFF moveUNTILthe THE
lever
BODYback IS to ‘hold’
FULLY DOWN.
• Lock the taildoorMAKE SURE THAT THE PTO IS DISENGAGED BEFORE
DRIVING OFF.
• If fitted, raise the stabiliser legs.
WHEN DRIVING
WHEN DRIVING

When UNLADEN leave the cab control in HOLD to minimise body

bounce.

When LOADING put the cab control in LOWER to ensure that no oil is
trapped in the cylinder and the entire load rests on the chassis. Then
return the control to HOLD when travelling.

11

18
 OIL
OIL

Dirty oil is the enemy of a hydraulic system. The cleaner the oil, the more
efficient the hoist's operation and the longer it's life. So always use clean
hydraulic oil for topping up or changing the oil in the tank.
Use oil to specification ISO6734/4 HM32 for temperatures between
-20°C to +30°C. Typical suitable trade names are:

CASTROL AWS32
ESSO VG32
GULF HYDRASIL 32
MOBIL DTE24
SHELL TELLUS 32

For other climates seek advice from your local distributor or direct from
Edbro.
Never put used oil in the tank. Never power wash near the breather-
ALWAYS use a cloth when cleaning.
To determine the oil level, remove the filler cap and check that the level
is within the max./min. marks as shown:

BLEEDING THE SYSTEM

If the hoist judders in 'LOWER', or the tubes operate out of sequence
when lowering, there may be air in the system. For early cylinders without
a bleed screw ( approximately, serial numbers before LG017000 /
LH002100) bleed the system as follows:

•
19
19
loosen the pressure outlet hose from the pump a little
 PROBLEM SOLVING

The following action can be taken without special tools.

If unsuccessful, call your nearest Edbro service dealer
(refer to www.edbro.com).

THE HOIST IS JERKY OR SLUGGISH

Air may be trapped in the system. Check oil level and then operate
the hoist to full stroke several times; any air will be dissipated back
to the tank. (see page 18)

THE BODY WILL NOT TIP

Make sure:
• The vehicle air pressure has had enough time to build up
(See vehicle operator’s manual)
• The oil in the tank is up to dipstick level (refer page 17)
• The pto switch is ‘in’ and pto is engaged (oil is circulating)
• The tipper lever is in ‘raise’
• There are no kinks in the oil pipes
• The quickly detachable couplings of the tractor and trailer, where
Applicable, are clean and screwed together tightly
• No air is leaking from the air pipes

THE BODY WILL NOT LOWER

Check pto has disengaged and warning light is out.

Put the tipper lever back in ‘raise’. Then:
• Rev the engine until the relief (overload) valve blows, i.E. Until you
Hear a high pitched noise coming from the tipper valve (page 3)
• Keep the engine revs going for five seconds
• Lower the body (page 11).
If the body still will not come down, put the tipper lever in ‘hold’,
PROP THE BODY, switch the PTO to ‘out’ and turn off the engine.
20
 PROBLEM SOLVING

THE BODY STOPS ON THE WAY UP

Lower the body as slowly as possible. Then make sure:

• The body is not overloaded or badly distributed

• The oil in the tank is up to dipstick level (refer page 16).

THE BODY WILL NOT STAY UP WITH THE TIPPER LEVER IN

‘HOLD’

Put the tipper lever back in ‘raise’ and lift the body. Then:
• Rev the engine until the relief (overload) valve blows, i.E. Until you
Hear a high pitched noise coming from the tipper valve (page 3)
• Keep the engine revs going for five seconds
• Put the tipper lever in ‘hold’.
If the body still will not stay up, lower the body.

EXCESSIVE NOISE
• Check pump speed / engine revs
• Check tank ball (if fitted ) is fully open
• check the oil level
• Check pipes for kinks and leaks
• Check suction hose is tightended correctly and unrestricted

21
21
Notes : Notes

22
Notes...

23
23
 PLEASE PUT THIS
OPERATOR MANUAL
IN THE VEHICLE CAB

For a full list of Edbro Service Agents

and To view the JOST World network,
Distributors, please refer to: please refer to:
www.edbro.com/dealerlocator www.jost-world.com

JOST UK Ltd,
Edbro House, JOST Werke,
Nelson Street, Siemensstr.2,
Bolton BL3 2JJ 63263 Neu-Isenburg
UK Tel: 0044 (0)1204 528 888 Germany Tel: 0049-6102-295-0

Edbro publication - Modified September 2019. Ref. number E5562/2